Vmac VR70 User manual

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VEHICLE MOUNTED AIR COMPRESSORS
System V90G120
2016-2011 Ford F250-F550 6.7L Diesel
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Installation Manual for VMAC
System V90G120
2016-2011 Ford F250-F550 6.7L Diesel
General Information..................................................................... 4
Before You Start....................................................................... 4
Additional Requirements .......................................................... 4
Part 1: Warranty and System ID................................................. 5
Part 2: Preparing for Installation............................................... 8
Part 3: Installing the Cooler, Bracket and Compressor.......... 14
3.1 Installing the Oil Cooler ...................................................... 14
3.2 Routing Battery Cables ...................................................... 15
3.3 Continuing Oil Cooler Installation....................................... 17
3.4 Installing Main Bracket....................................................... 19
3.5 Battery Cable and Relocated Battery Box.......................... 31
3.6 Washer Bottle..................................................................... 36
3.7 Air Filter Box....................................................................... 39
Part 4: Installing the Tank and Hoses....................................... 51
4.1 Installing the Tank and Brackets........................................ 51
4.2 Installing the Hoses............................................................ 53
4.3 Adding Oil to the System.................................................... 54
Part 5: Installing the Control Components .............................. 55
5.1 Routing the Wiring.............................................................. 56
5.2 Installing the components................................................... 57
5.3 Connecting the In-cab Wiring............................................. 61
5.4 Completing and Testing the Installation............................. 64
Part 6: Finishing the Installation................................................ 66
6.1 Before Starting the Engine Checklist.................................. 66
6.2 Safety Test ......................................................................... 66
6.3 Setup, Performance Testing and Adjustments................... 69
6.4 Auxiliary Air Receiver ......................................................... 70
Accessory Products from VMAC ............................................... 71

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!
Document #1930190
Installation Manual for VMAC System V90G120
2016-2011 Ford F250-F550 6.7L Diesel
Changes and Revisions
Version
Revision Details
Revised by/date
Checked by/date
Reviewed by/date
Implemented
E
ECN 13-013, ECN 14-018
JR 30 Apr 2014
MH 06 May 2014
RD 06 May 2014
12 May 2014
F
ECN 14-047
JR 14 Nov 2014
MH 20 Nov 2014
DB 19 Nov 2014
20 Nov 2014
G
ECN 18-135 Washer Btl
MSP 11 June 2018
KM/GB 12 Jun 2018
AWG 12 Jun 2018
13 June 2018
Important Information
This symbol is used to call your attention to instructions
concerning your personal safety. Watch for this symbol; it
points out important safety precautions, it means “attention,
become alert! Your personal safety is involved. Read the
message that follows and be alert to the possibility of personal
injury or death. Be alert; your safety is involved. While it is
impossible to warn about every conceivable hazard, let good
common sense be your guide.
This symbol is used to call your attention to additional
instructions or special emphasis on a specific procedure.
The information in this manual is intended for certified VMAC
installers who have been trained in installation procedures and for
people with mechanical trade certification who have the tools and
equipment to properly and safely perform the installation. Do not
attempt this installation if you do not have the appropriate
mechanical training, knowledge and experience.
Follow all safety precautions for under hood mechanical work. Any
grinding, bending or restructuring operations for correct fit in modified
trucks must follow standard shop practices.
All hoses, tubes, and wires that are rerouted or shifted
during installation must be secure so that they do not
contact excessively hot areas or sharp edges. Where
possible, use rubber coated P-clips. Follow the routing
suggestions in this manual and cover all hoses with the
supplied plastic loom.
!

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These instructions are a general guide for installing this system on
standard production trucks and do not contain information for
installation on non-standard trucks. This system may not fit special
order models or those which have had other changes without
additional modifications. If you have difficulty with the installation,
contact VMAC.
The VMAC warranty form is located at the back of this manual. This
warranty form must be completed and mailed or faxed to VMAC at
the time of installation for any subsequent warranty claim to be
considered valid.
To order parts, contact your VMAC dealer. Your dealer will ask for
the VMAC serial number, part number, description and quantity. To
locate your nearest dealer, call 1-888-241-2289.
Copyright 2018
All trademarks used in this manual are the property of the respective copyright holder.
The contents of this manual may not be reproduced in any form without the express
written permission of VMAC, 1333 Kipp Road, Nanaimo, BC V9X 1R3.
Printed in Canada

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General Information
Before You Start
Read this manual before attempting installation so that you can
familiarize yourself with the components and how they fit on the
truck. Identify variations for different model years and different
situations that are listed in the manual. Open the package, unpack
the components and identify them.
All fasteners must be torqued to specifications. Use manufacturers
torque values for OEM fasteners. Apply Loctite 242 or equivalent on
all engine-mounted fasteners. Torque values are with Loctite
applied unless otherwise specified.
STANDARD GRADE 8 NATIONAL COARSE THREAD
Size
1/4
5/16
3/8
7/16
1/2
9/16
5/8
¾
Foot-pounds (ft-lb)
9
18
35
55
80
110
170
280
Newton meter (N•m)
12
24
47
74
108
149
230
379
STANDARD GRADE 8 NATIONAL FINE THREAD
Size
3/8
7/16
1/2
5/8
¾
Foot-pounds (ft-lb)
40
60
90
180
320
Newton meter (N•m)
54
81
122
244
434
METRIC CLASS 10.9
Size
M8
M10
M12
M14
M16
Foot-pounds (ft-lb)
19
41
69
104
174
Newton meter (N•m)
25
55
93
141
236
Additional Requirements
Special Tools
Pneumatic fan wrench removal set (such as Lisle 43300) or a
manual fan pulley holder (such as KD3900)
OEM flywheel locking tool part number J42386.

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!
Hose Information
Depending on other installed equipment, it might be
necessary to move the air/oil separation tank from its
intended location. The hoses used in VMAC compressor
systems have a specific inner liner that is compatible with
our compressor oil. Use of hoses other than those supplied
or recommended by VMAC may cause compressor damage
and may void your warranty. Please contact VMAC for
replacement hoses and further information.
Part 1: Warranty and System ID
□Complete the warranty form. The VMAC warranty form is located
at the back of this manual. This warranty form must be
completed and mailed or faxed to VMAC at the time of
installation for any subsequent warranty claim to be considered
valid.
System Identification and Operating Instructions
The System Identification Number Plate must be attached to the
vehicle at the time of installation. This plate provides information that
allows VMAC to assist in customer inquiries and the ordering of
parts.
□Mark and drill two 7/64”holes in the top of the cross member in
front of the OEM air filter box. Secure the plate with supplied
self-tapping screws
□Clean cross member beside the number plate and stick the
VMAC belt routing diagram to the cross member.
□Apply battery warning label to driver side of primary cooling
reservoir.

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□As part of the installation process, ensure that the safety and
operational instruction decal is affixed in an obvious location so
that it can be seen by vehicle operators. A good spot for this is
usually on the inside of the door or on the panel underneath the
steering wheel. (Figure 1.1).
Figure 1.1

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□To alert any technicians that may service the vehicle, affix the
servicing caution/contact label in the engine compartment near
the hood latch in a visible location. Thoroughly clean the
selected area before affixing the label (figure 1.2)
Figure 1.2

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Part 2: Preparing for Installation
Preparation for installation is very important. Missing an item can
cause problems in the installation or even damage to components.
Check off each item as it is completed so that you do not miss any
preparation steps.
Ensure that you have filled out the VMAC Warranty
Registration. Install the System Identification Number Plate
and Operational Instruction Decal. (Please see Part 1 for
details).
□Locate the blunt-cut OEM SEIC wire harness, on the driver’s
side just below the OBDII port. You will need to find the
transmission park signal (blue with grey stripe wire).
□Use a multi-meter to verify the transmission park signal. Turn the
key to the RUN position (do not start the truck), as to supply
power to the dash display. The resistance should read close to
0-ohms in park and open circuit in all other gears. If this is
correct, put the car in park and turn the key to the off position.
There are multiple blue wires with various coloured stripes.
The transmission park signal needs to be electrically
verified with a multi-meter to ensure the correct wire is read.
□Mark transmission park signal wire for connection later in Part 5:
Installing the Control
Components.
□Disconnect batteries (both driver and passenger side).
□Drain coolant from both the primary and secondary radiators
(drain for primary coolant is on driver’s side, secondary coolant is
on passenger side). Start with the secondary radiator. Save
coolant to be reused later. Close drain caps when coolant has
been drained.

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□Remove passenger side battery bracket and battery.
□Disconnect the mass air flow sensor from the top of the filter box.
□Remove filter box (both upper and lower sections).
□Remove tube and resonator that connects the filter box to the
turbo intake.
□Cover turbo intake.
□Remove passenger side hood strut and hood strut ball stud from
the hood, (save for later use).
□Remove lower hood strut ball stud from inner fender.
□Remove positive terminal block and wiring connector panel from
passenger side battery box. To remove wiring panel pry up.
Positive terminal block has one clip and slides up to remove.
□Disconnect windshield washer tube from joint above passenger
side battery box on top of firewall.
□Unplug wiring harness from windshield washer pump and
remove wiring from front lower passenger side battery box.
□Unplug glow plug module connectors from bottom of passenger
side battery box (3 connectors).
□Remove the bolt from wheel well that secures inner fender to
battery box.
□Remove passenger side battery box (save bolts for later use).

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□Remove glow plug module from bottom of passenger side
battery box (Torx T30 bolts) (save module for later use).
□Disconnect hoses from secondary coolant reservoir (attached to
passenger side of fan shroud) and remove reservoir from fan
shroud.
□Remove upper secondary coolant hose (top hose going to water
pump on passenger side of engine).
□Cut plastic cuff securing hose on secondary rad hose carefully to
preserve fitting (discard band and hose) (Figure 2.01).
Cut Plastic Cuff To
Remove Connector
Upper Secondary
Radiator Hose
Figure 2.1
□Install supplied hose back on connector and secure with supplied
hose clamp (Figure 2.2).

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Supplied Hose
OEM Quick
Connect
Supplied Hose
Clamp
Figure 2.2
□Install hose coupling and flexible hose to open end of modified
secondary coolant hose. Leave about 1” gap between hoses
and secure with supplied hose clamps.
□Remove plastic wire guide from front of EGR on passenger side
of engine (two bolts securing to EGR and plastic ties securing to
wire). Save bolts for attaching the inlet valve brace later and
discard plastic. (Figure 2.3).
Figure 2.3

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□Using knife cut insulated heat shield if required to clear hose.
Install modified hose back on secondary water pump. Ensure
notches on OEM quick connector align with notches on
secondary water pump. Point elbow towards rear of truck
(opposite to the original direction). Ensure hose is not kinked,
(rotate the hose on the OEM quick connect, if required, to
remove any kinks). Hose must run underneath the injector wiring
harness.
□Ensure OEM locking clip is engaged on plastic elbow. Loop hose
towards front of truck.
□Remove bolt securing power steering reservoir to upper fan
shroud. DO NOT remove hose from reservoir. Slide reservoir up
out of clip securing it to the upper fan shroud.
□Remove 5 bolts (3 on driver’s side and 2 on passenger side) and
wire clips securing upper fan shroud and remove upper fan
shroud from truck.
□Unplug fan wire (unplug connector closer to the engine, not the
one right on the hub of the fan). Remove long bolt securing fan
wiring harness to engine and discard.
□Remove the fan (right-hand thread) and pull it out of the engine
bay.
For ease of fan removal and installation, it is recommended
that a pneumatic fan wrench removal set (such as Lisle
43300) or a manual fan pulley holder (such as KD3900) is
used.
□Remove fan stator (the lower shroud can be left in place if the
stator is rotated to clear the lower lip).
□Remove upper passenger side fan stator mount and save for use
later.

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□Release tension on OEM belt (leave belt routed correctly on
passenger side of engine).
□Remove 2 bolts from secondary water pump (Figure 2.4).
Remove OEM Bolts From
Secondary Water Pump
Figure 2.4

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Part 3: Installing the Cooler,
Bracket and Compressor
3.1 Installing the Oil Cooler
□Remove lower primary coolant hose (attached to the primary
cooler and engine) (Figure 3.1).
To
Engine
From
Radiator
Figure 3.1
□Cut the plastic cuff securing the OEM quick connect to engine
side coolant hose (discard OEM quick connect) (Figure 3.2).
Cut Cuff
OEM Quick
Connect
Figure 3.2
□Cut the radiator side coolant hose 8” from the OEM quick
connect (discard short section of hose with OEM quick connect)
(Figure 3.3).

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OEM Quick
Connect
Discard This
Section
8”
Figure 3.3
3.2 Routing Battery Cables
□Apply loom to supplied battery cable extensions.
Note: The red and the black battery cables will follow the
same route!
□Route the supplied positive/red battery cable between the frame
and body from the re-located battery location that will be under
the driver side. Leave 20” of cable to the rear of the body mount
hanging under driver side door.
□Continue routing the cable above the truck electrical harness and
below the two metal power steering lines.
□Continue routing, careful to avoid the steering column, around
front of the steering box until the cable reaches the electrical
harness under/beside the fan shroud.
□Feed cable along fan shroud following other truck wiring
harness.
□Continue following truck wiring harness under the air intake and
metal bracket. Route along the inner fender plastic wire guide
tray under fender and follow OEM positive cable wire harness to
relocated battery positive terminal.

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□Route the negative battery cable from the relocated battery
location and follow the positive battery cable. Continue routing
until under the fan shroud and in such a way it will remain clear
of the crank pulley and any other sharp or moving objects.
□Remove the OEM negative battery block bolt attaching the OEM
negative battery cable located beside the engine side coolant
OEM quick connect (Figure 3.4).
For ease of removal the OEM negative battery block bolt
should be removed with the engine side coolant hose
disconnected. Figure 3.4 shown with coolant hose
connected to illustrate the OEM negative battery bolt
location.
OEM Negative
Battery Engine
Block Bolt
Engine Side
Coolant Hose
Front of
Engine
Figure 3.4
□Install the supplied negative battery cable lug on top of the
existing OEM negative battery cable lug. Orientate the cable so
that it travels down and under the existing vehicle battery tray
facing the front of the vehicle towards the fan shroud. Reuse the
existing OEM negative battery bolt.
□Secure battery cables with tie-straps as required as to clear the
crank pulley and other moving parts.

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3.3 Continuing Oil Cooler Installation
Do not strike the impact sensor as this could cause the
airbags to actuate. (Figure 3.5)
□Position the cooler in the center of the cross-member so that it is
just above the sway bar with the oil ports facing up (Figure 3.5).
Fog Light Connector
Location
Impact Sensor
Location
Cross Member
Figure 3.5
□Apply Loctite then install bolts through the flat mounting strap
and place them on the front of the cross member on each side of
the impact sensor. Note the impact sensor is located in the
center of the cross-member; the driver side wire connection is for
the fog lights if equipped (Figure 3.5).
□Thread the bolts into the matching holes on the cooler mounts
hand tight only, this will allow the cooler to be repositioned if
necessary after the coolant hoses have been attached (Figure
3.5).
□Install the radiator side coolant hose and secure with supplied
hose clamp (Figure 3.6).
!

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Figure 3.6
□With the radiator side coolant hose secured tighten the cooler
mount bolts to specification.
□Install the engine side coolant hose and secure with supplied
hose clamp (Figure 3.6). Note, it may be necessary to trim the
cooler end of the coolant hose, do so as required if any kinking
of the hose occurs.
□Apply hose protection to 1/2" oil hoses.
□Connect the shortest 1/2" hose to the passenger side of the
cooler and orientate as shown (Figure 3.7).
□Connect the longest 1/2" hose to the driver side of the cooler and
orientate as show (Figure 3.7). (Note the cooler hoses must be
installed before the fan shroud is installed).
Figure 3.7